Rifeng PE(X)/AL/PE(X)Multilayer Piping System Installation Guidelines

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1 Rifeng PE(X)/AL/PE(X)Multilayer Piping System Installation Guidelines Note:Rifeng PE(X)/AL/PE(X)Multilayer Pipe thereinafter is briefly called PAP pipe in the context. (Updated June 2008)

2 Index 1. Rifeng PAP pipe description P-3 2. Marking and explanation P-3 3. System design and application classifications P-4 4. Introduction to Rifeng fittings and tools P Fittings available P Reamers available P Cutting tools available P Pipe bending tools available P Pressing tools available P-6 5. Rifeng PAP pipe and fitting connection technique P Pipe preparation P Rounding and beveling P Rounding and beveling the pipe of φ14-φ32 P Rounding and beveling the pipe of φ40-φ75 P Checking the profile of pipe after rounding and beveling P Bending the pipe P Connecting pipe and fitting P Connecting F1 fitting P Connecting F5 series crimp fittings P Connecting F5 fitting with pipe φ14-φ32 P Connecting F5 fitting with pipe φ40-φ75 P Connecting F9 series crimp fittings P Connecting F9 fitting with pipe φ14-φ32 P Connecting F9 fitting with pipe φ40-φ63 P Installation procedure for Rifeng PAP Piping System P Mounting technology P Protection P Example installation P Pressure testing with water after Rifeng PAP piping installation P Pipe line flushing P-19 Note:Rifeng PE(X)/AL/PE(X)Multilayer Pipe thereinafter is briefly called PAP pipe in the context. 2

Rifeng PAP Piping System Installation Guidelines This manual contains recommended installation instructions for Rifeng PAP piping systems.

3 Rifeng PAP Piping System Installation Guidelines This manual contains recommended installation instructions for Rifeng PAP piping systems. Failure to observe these installation instructions may result in substandard performance of the system. Rifeng Piping Systems expressly disclaim any responsibility or liability for substandard performance resulting from failure to comply with the installation instructions. 1. Rifeng PAP pipe description Rifeng PAP pipe combines the benefits of both metal and plastic pipes. The inline welded aluminium tube is absolutely safe against oxygen penetration. It compensates for the snap-back forces and the linear expansion caused by temperature changes. The basis of the system is simple, safe and fast pipe installation: simply bend by hand,cut to length, ream and bevel, join together, screw or press,done. 2. Marking and explanation All Rifeng PAP pipes are marked with nominal sizes,pressure/temprature ratings,materials,approval marks and applicable standards. See following example for marking. 012A RIFENG PEX/AL/PEX B ASTM F1281 Q/RF1:2005 Tmax=95 1MPa 000m Explanation 012A0111 Batch number Production time(yyyy-mm-ddhhmmss) RIFENG Manufacturer and logo PEX/AL/PEX Pipe materials/structure B Product type & size (For available types please see the following clause 3) ASTM F1281 Q/RF1:2005 Reference standard Tmax=95 Maximum design temperature 1MPa Pressure Rating 3

4 3. System design and application classifications Application conditions and classifications of the pipes. The basic Rifeng PAP piping system components can be used in the areas of plumbing, underfloor heating,radiator heating and gas applications, etc. Types of pipe Materials Applications Service temperatures Maximum working pressure A HDPE/AL/HDPE Cold water supply -40 ~+60 10bar B PE-RT/AL/PE-RT Hot water supply, -40 ~+95 10bar underfloor heating etc. B1 PEX/AL/PEX Hot water supply, -40 ~+95 10bar underfloor heating, radiator heating,etc. C MDPE/AL/HDPE Gas or natural gas -20 ~+60 5bar supply 4. Introduction to Rifeng fittings and Tools A complete system is made of Rifeng PAP pipes, fittings and manifolds. It is possible to cause leakage to connect other producers fittings with Rifeng PAP pipes,vice versa. Rifeng provides different types of fitting to customers. Rifeng fittings are forged from strong brass,depending on different areas and applications,majorly 3 types of brass are used for Rifeng fitting production:dezincification Resistant brass according to German DVGW standard,uns C37700 brass according to American ASTM standard,and normal brass. F1, F5 & F 9 fitting series are available to connect with PAP pipes. F1 series work by insertion of the fitting into the pipe and screwing compression nut and C-shape split ring over the pipe. While the F5 and F9 series work by insertion of the fitting into the pipe and pressing stainless sleeve over the pipe,providing quick and safe installation. 4.1 Fittings available F1 series: Special tool is not necessary. 4

5 F5 series: "U" pressing jaws and clamping tools are necessary. F9 series: "TH" pressing jaws and clamping tools are necessary. 4.2 Reamers available Made of plastic or steel, to be inserted into the pipe for beveling and rounding the Rifeng PAP pipe, before the pipe is installed onto the fitting. Plastic reamer (ZYD14-16,ZYD16-20,ZYD20-32) Use for rounding and beveling pipes 14-32, application for F1,F5 and F9 series Fittings. Desk reamer(jd-40-75(z)) Use for rounding pipes of sizes 40-75, application for F5 and F9 series fittings Caution: For pipe sizes 40-75,after rounding by desk reamer,installer should not insert fitting yet,beveling must be followed with JD T-reamer. T-reamer,,one reamer for one pipe size. JD-1014,JD-1216, JD-1418, JD-1620, JD-2025, JD-2632,use for rounding and beveling pipes 14-32, JD-3240, JD-4150, JD-5163, JD-6075,use for beveling pipes after rounding by desk reamer JD-40-75(Z). Lengthened T-reamer (JD-3240(L), JD-3240(L), JD-4150(L), JD-5163(L), JD-6075(L)) Use for rounding and beveling pipes Caution: The lengthened T-reamer is for both rounding and beveling at one step,so not necessarily to be used with desk reamer for rounding and beveling. 5

4.3 Cutting tools available Designed for smooth, even cutting, the tool's jaw should fit firmly over the pipe to allow a square, burr-free cut. Pipes cutter (GJ III) Use for cutting PAP pipes 14-32.

6 4.3 Cutting tools available Designed for smooth, even cutting, the tool's jaw should fit firmly over the pipe to allow a square, burr-free cut. Pipes cutter (GJ III) Use for cutting PAP pipes Pipes cutter (QGQ) Use for cutting PAP pipes Pipe bending tools available Allow to bend PAP pipe at bending radius of 5 times the pipe Outside Diameter(OD). Pipe bending tool (WGQ(6in1) ) Blending spring, external and internal available (WH-14,16,18,20,26,32) 4.5 Pressing tools available Rifeng supplys manual pressing clamps(rifeng SYQ series) and hydraulic pressing clamps(rifeng YYZ series) only. For using other suppliers dynamoelectric pressing clamps, please consult with authoritative Rifeng technician for approval. Suitable "U"-profile pressing jaws Suitable "U"and "TH"-profile pressing jaws (SYQ14-20) (SYQ14-32) Rifeng Integral hydraulic tool (YYZ) Rifeng Separated hydraulic tool (YYZ III) 6

Both integral and separated hydraulic tools share the same jaws and the specifications are shown as

hydraulic tools Separated hydraulic tool Separated hydraulic tool 5.

1 Pipe preparation Cutting pipe to wanted length,the pipe should be cut in perpendicular direction.

2 Rounding and beveling The pipe end hole must be beveled correctly in case of damage on the sealing

7 Both integral and separated hydraulic tools share the same jaws and the specifications are shown as below: Specifications YYQ-14-32II YYQ-25-50II YYQ-63-75II Suitable tool Integral and Separated hydraulic tools Separated hydraulic tool Separated hydraulic tool 5. Rifeng PAP pipe and fitting connection technique 5.1 Pipe preparation Cutting pipe to wanted length,the pipe should be cut in perpendicular direction. * GJ III cutter for pipe φ14-φ32 *. QGQ-75 cutter for pipe φ40-φ Rounding and beveling The pipe end hole must be beveled correctly in case of damage on the sealing O-ring during fitting installation and also to let the fitting insert get into the pipe easily Rounding and beveling the pipe φ14-φ32 Round and bevel the pipe end with the Rifeng reamer (14-32 ZYD Plastic reamer or JD T-reamer). 7

5.2.2 Rounding and beveling the pipe φ40-φ75 Rounding the pipe with the desk reamer and

Optional:Both beveling and rounding with the JD-(L) Lengthened T-reamer.

by T-reamer are two separate steps but easy to operate.

8 5.2.2 Rounding and beveling the pipe φ40-φ75 Rounding the pipe with the desk reamer and following by beveling with JD T-reamer. The depth of beveling should be over 2mm. Optional:Both beveling and rounding with the JD-(L) Lengthened T-reamer. The depth of beveling should be over 2mm Caution:Rounding by desk reamer and then beveling by T-reamer are two separate steps but easy to operate.both rounding and beveling by Lengthened T-reamer just need one step but is more difficult to operate Checking the profile of pipe after rounding and beveling Checking, installer should make sure the pipe end profile is rounded and beveled smoothly,and the scraps caused by beveling are removed and cleaned from inside,outside and end of the pipe. 1.Check the pipe 2.Left one shows the pipe before rounding and beveling, the right one shows the pipe after rounding and bevelling 3. Get rid of the scraps caused by beveling. 8

5. 3 Bending the pipe * Bending directly Bending the pipe directly to the required radius by hands.

* Bending with inside bending spring Notice: Bending PAP pipe without tools should be slowly and it only

Insert the inside bending spring into the pipe, a little part of the spring should be left outside the pipe,

* Bending with outside bending spring Insert the pipe into the outside bending spring, and move the spring

9 5. 3 Bending the pipe * Bending directly Bending the pipe directly to the required radius by hands. Recommended distance for two hands is 40 cm. * Bending with inside bending spring Notice: Bending PAP pipe without tools should be slowly and it only suits big bending curve, after bending installer must re-check to ensure no deformation on the pipe. Insert the inside bending spring into the pipe, a little part of the spring should be left outside the pipe, bend the pipe to the bending radius required, the bending radius should be over 5D. * Bending with outside bending spring Insert the pipe into the outside bending spring, and move the spring to the point where pipe should be bended. then bend the pipe with hand, the bending radius should be over 5D. * Bending with bending tool Bending the pipe with the bending tool, the pipe can be bended precisely in 5D.. 9

4 Connecting pipe and fitting Rifeng Piping Systems provides F1 screw fitting, and F5 & F9 crimping fittings for PAP system, all the fittings are certified by tests.

10 Notice: The minimum bending radius is 5D (D=outside diameter of the pipe) Do not damage the pipe in bending. 5.4 Connecting pipe and fitting Rifeng Piping Systems provides F1 screw fitting, and F5 & F9 crimping fittings for PAP system, all the fittings are certified by tests. F1 is suitable for general customers, F5 and F9 are suitable for professional users as quicker and safe installation. WARNING: It is the installer's responsibility to choose correct fitting components. Rifeng Piping Systems do not guarantee or in any way warrant the installation of Rifeng PAP systems due to the wide variance in installation practices. IMPORTANT: Mixing use of Rifeng pipes with other producers fittings,or Rifeng fittings with other producers pipes,or wrong use of tools/components/fittings without Rifeng authoritative technician s permission during installation might cause leakage. User should consult us for suitable fittings or tools Connecting F1 fitting (1)Check the fitting and pipe, the pipe should be rounded and beveled, the fitting and pipe specifications should be compatible. (2). Take off the compression nut and split ring from the fitting 10

(3). Slide the compression nut onto the pipe first, then the split ring (pay attention to the direction of nut) (4).

Note:Please aim and straight push,don't screw when you put the fitting insert into the pipe. (5).

2 Connecting F5 series crimp fittings Before connecting crimping fittings, user must make sure pipes are well and truly

11 (3). Slide the compression nut onto the pipe first, then the split ring (pay attention to the direction of nut) (4). Aim and straight push the fitting insert into the pipe until the pipe reaches the end of fitting corner. Note:Please aim and straight push,don't screw when you put the fitting insert into the pipe. (5). Screw-tighten the compression nut with the fitting body by hand (6).Screw-tighten the fitting with the spanner Connecting F5 series crimp fittings Before connecting crimping fittings, user must make sure pipes are well and truly prepared Connecting F5 fitting with pipe φ14-φ32 (1).Check the fitting and pipe,the pipe end should be rounded and beveled, the fitting and pipe specifications should be compatible. 11

12 (2).Aim and straight push the fitting insert into the pre-sleeved pipe, until the pipe out-surface can be seen through the inspection holes. Note:Please aim and straight push,don't screw when you put the fitting insert into the pipe. Important: We provide "U" and "TH" profile pressing jaws for crimp series fittings. "U" profile pressing jaw is used for F5 series, "TH" profile pressing jaw is used for F9 serie fittings. Operation instructions of the tools also must be observed. Please use the pressing tools supplied by Rifeng or certified by Rifeng to ensure the installation quality. In addition, we recommend collaborative well-know REMS tools. Warning: Rifeng Piping Systems disclaim any responsibility or liability failures due to unauthorized tools or fittings application in Rifeng PAP pipe system. (3). Choose correct size pressing jaws and clamping tool according to the pipe size 12

(4). Position the jaws so that their ends align with the press sleeve s end

While the jaw is completely closed, the handles will be self-locked.

the pipe is well rounded and beveled, and select correct fitting according to

13 (4). Position the jaws so that their ends align with the press sleeve s end which is by the plastic ring,close the pressing clamp completely. (5).While the jaw is completely closed, the handles will be self-locked. Open the handles and remove the pressing tool from the fitting and installation is accomplished Connecting F5 fitting with pipe φ40-φ75 Before installation,please make sure the pipe is well rounded and beveled, and select correct fitting according to pipe. Then follow below instructions. (1).Pipe and fitting preparation before pressing Placing the pipe into the sleeve until the pipe end reaches the sleeve s bent end. 13

Inserting the fitting into the sleeved pipe,till the sleeved pipe end reaches the fitting shoulder block.

de or contact your local REMS service operations which spread worldwide. (2).Preparation and pressing with Rifeng YYF III separated hydraulic tool.

14 Inserting the fitting into the sleeved pipe,till the sleeved pipe end reaches the fitting shoulder block. Note:Please aim and straight push,don't screw when you put the fitting insert into the pipe. Note: In addition to the following Rifeng pressing tools, U profile REMS tools are also recommended to press our large size F5 fittings (U14-63 REMS tools are available for now, and U75 REMS tool is being tested for approval). For REMS tool guide please see or contact your local REMS service operations which spread worldwide. (2).Preparation and pressing with Rifeng YYF III separated hydraulic tool. Connecting the oil tube with the manual hydraulic pump and the clamp head, make sure the connection is absolutely tight. Choosing the right size of jaw for the corresponding pipe, and then releasing the pin from the clamping head. Installing the jaw in the clamping head and shutting the pin back on position 14

Releasing the lock from the handle of the

the clamping head by rotating the switch at

the jaw by releasing the tail, make sure

by operating the handle of the pump with up

15 Releasing the lock from the handle of the pump. Releasing the hydraulic pressure in the clamping head by rotating the switch at anti-clockwise direction (left picture), and then rotating the switch back at clockwise direction (right picture) until it is tightened. Opening the jaw by pressing its tail with hand and placing the installed fitting inside the pressing surface, then closing the jaw by releasing the tail, make sure the sleeve is totally assembled with the pressing surface. Pumping the pressure to the clamping head by operating the handle of the pump with up and down direction, repeating this procedure until the jaw is completely closed. Releasing the installed fitting from the jaw. 15

16 Warning: It is not allowed to press fitting twice or more. Incorrectly pressed fitting should be replaced. Operation instructions of all these tools must be respected, installer should read these instructions in details before using Rifeng manual pressing clamp tools and hydraulic pressing tools Connecting F9 series crimp fittings Before connecting crimping fittings, user must make sure pipes are well and truly prepared Connecting F9 fitting with pipe φ14-φ32 (1).Check the fitting and pipe, the pipe end should be rounded and beveled, choose the right size pre-sleeved fitting for the pipe, the fitting and pipe specifications should be compatible. (2).Aim the pipe end at the ring-shape hole of the pre-sleeved fitting,and straight push the fitting insert into the pipe until it reaches the plastic block. Check the inserting depth by looking through the inspection holes on the sleeve shoulder to ensure that the pipe is completely inserted. Note:Please aim and straight push,don't screw when you put the fitting insert into the pipe. (3). Choose correct size "TH"-profile press jaws and clamping tool according to the pipe size. Notice: Installer could choose "TH"-profile jaws and Rifeng manual pressing tools or REMS TH -profile electric pressing tool, operating instruction of REMS tools must be observed. (4). Ensure the margin of the plastic block and the sleeve are at the right position in the jaw; the margin of the plastic block must be placed into the groove of the tong head. Margin Groove Note: The margin of the plastic block should be placed into the tong head, there is a groove in the tong head for the margin section when you press. 16

17 (5) Operating the tool by trigger and holding the trigger until the pressing process is finished. Releasing the pressed fitting from the jaw Connecting F9 fitting with pipe φ40-φ63 Rifeng currently does not provide pressing tools for F9 series fittings.we recommend REMS "TH"-profile pressing tool for pressing F9 series fittings Please contact REMS ( for the operation instructions of tools. 6. Installation procedure for Rifeng PAP Pipe System Rifeng piping system is excellent choice for tap water and underfloor heating, it could be connected using the high quality Rifeng PAP pipe with outside diameter ranging 14-75mm Mounting technology Rifeng Piping Systems provides different series of fixing sockets to mount pipes on perforated tape or concrete. If the Rifeng PAP pipe system is installed directly in the concretes, any permanent pipe fittings must have suitable protection against corrosion. U-clip Plastic socket closed/open aluminium socket fixed/slide socket Rifeng PAP pipe socket holds pipe in position and prevents strain on fittings when the pipe is bent.please refer to following table for support distance between two sockets: Table for support distance Nominal diameter (mm) Vertical (mm) Horizontal (mm) Nominal diameter (mm) Vertical (mm) Horizontal (mm)

6.2 Protection Fire protection, the main goal of fire protection is to hinder fires. If a fire occurs, then the second goal of fire protection is to minimize damage.

level as an equivalent sized metal pipe. Insulating solutions with pre-insulated Rifeng PAP pipes Caution: Pipe with corrugated pipe Pipe in insulation pipe Maximal working temperature: 95.

18 6.2 Protection Fire protection, the main goal of fire protection is to hinder fires. If a fire occurs, then the second goal of fire protection is to minimize damage. Thermal protection, Rifeng PAP Pipe has better insulation property when compared with bare copper or steel pipes, for practical reasons we recommend that Rifeng PAP pipe is installed to the same level as an equivalent sized metal pipe. Insulating solutions with pre-insulated Rifeng PAP pipes Caution: Pipe with corrugated pipe Pipe in insulation pipe Maximal working temperature: 95. Maximum continuous operating pressure: 10 bar at a continuous operation temperature of 70 tested hydrostatic stress performance of 50 years, safety factor 1.5. Please contact us at service@rifeng.com or if you require additional explanation of the instruction. 6.3 Example installation The drawings below show a typical domestic property where Rifeng plumbing system has been installed to the ground floor. Caution:Pressure testing should be performed right after piping installation,if there is no leakage found after pressure testing, the piping system can then be buried with concretes,for maximum allowed diameters and shapes of hard blocks which might be included in the burying concretes,please follow local codes or regulations.rifeng Piping Systems expressly disclaim any responsibility or liability for any damage on the established piping system resulting from hard blocks included in buring concretes with exceeding diameters or out-of-regulation sharp shapes. 18

19 The following pressure testing with water is just for installer s reference,installer can use local installation practices or codes for intallation checking. 7. Pressure testing with water after Rifeng PAP piping installation A pressure gauge must be connected at the lowest point of the installation being tested and a visual inspection of all pipe connections is to be made before pressure testing with water. Make sure a pressure difference of 0.1 bar can be read by the pressure measuring instruments. Ensure no mistakes in all connections,then the installation system should be filled with filtered tap water(please pay attention to protection against frost and icing) and vented. Shut-off valves before and after boilers and tanks are to be closed so that the test pressure is kept away from the rest of the system. Build pressure up to maximum permissible operating pressure plus 5 bar(for example,if the maximum permissible operating pressure is 10 bar then the test pressure should be 15 bar). Wait until the temperature equilibration between water in pipe and ambient, if necessary, the test pressure must be re-built after the waiting period. Preliminary test is to re-establish the test pressure two times within 30 minutes at intervals of 10 minutes. After a further 30 minutes the test pressure must not drop by more than 0.6 bar. Main test is to be run directly following the preliminary test. The test is considered pass if the test pressure has not dropped by more than 0.2 bar after a further two hours. After test complete,all fittings need to be checked for possible leakage.the test time and pressure dropped off the preliminary and main test must be recorded for plumber and user reference. 8. Pipe line flushing Total system is to be flushed thoroughly as soon as possible after installation of the piping and following the 19

20 pressure test. To ensure a sufficient flushing effect, this procedure could be based on pulsating flow of water or water and air. Warning: Once the test and flush complete, you should expel water with compressed air. Because the test water might cause freezing or damage of the piping system in winter prior to use. Rifeng Piping Systems claim this Rifeng PAP Piping System Installation Guidelines does not include all cases possible met during Rifeng PAP piping system s services. If users meet any new case or have any questions on above guidelines, please contact us by service@rifeng.com or by tel:

CONEX Works, Santry Avenue, Dublin 9, Ireland Tel: (0) Fax: (0)

CONEX Works, Santry Avenue, Dublin 9, Ireland Tel: 00 353 (0)1 842 6255 Fax: 00 353 (0)1 842 6134 Email: sales@sanbra.ie MULTILAYER PIPING SYSTEMS I.S. EN ISO 21003-1:2008 NSAI Certified PRODUCT OVERVIEW